Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


Note: The fuel system hose/pipes are serviceable individually or as a complete fuel/brake bundle assembly. The following procedure is servicing the fuel hose/pipes individually.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Before you service any fuel system connection, relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Fuel Pressure Relief).
3. Remove the exhaust and exhaust heat shields. Refer to Exhaust System Replacement (V8 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V8 - Complete) (Exhaust System Replacement (Complete))Exhaust System Replacement (V6 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V6 - Complete) (Exhaust System Replacement (Complete)).
4. Remove the engine. Refer to Engine Replacement (Removal and Replacement).
5. Disconnect the fuel and evaporative emission (EVAP) lines at the fuel tank. Refer to Fuel Tank Replacement (Service and Repair).
6. Disconnect the fuel and EVAP) lines at the engine compartment.




7. Remove the retaining bolts (1) and the retaining nuts (1) securing the rear stone guard.




8. Remove all the fuel line bracket pop rivets securing the fuel and EVAP pipes to the vehicle body.




9. Remove all the fuel line bracket pop rivets (1, 2, 3) securing the fuel and EVAP pipes to the body tunnel.
10. Remove the fuel and EVAP lines from the vehicle.

Installation Procedure

1. Install the fuel and EVAP lines to the vehicle.




2. Install all the fuel line bracket pop rivets (1, 2, 3) securing the fuel and EVAP pipes to the body tunnel.




3. Install all the fuel line bracket pop rivets securing the fuel and EVAP pipes to the vehicle body.




4. Install the retaining bolts (1) and the retaining nuts (1) securing the rear stone guard.
5. Connect the fuel and EVAP lines at the engine compartment.
6. Connect the fuel and EVAP lines at the fuel tank. Refer to Fuel Tank Replacement (Service and Repair).
7. Install the engine. Refer to Engine Replacement (Removal and Replacement).
8. Install the exhaust and exhaust heat shields. Refer to Exhaust System Replacement (V8 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V8 - Complete) (Exhaust System Replacement (Complete))Exhaust System Replacement (V6 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V6 - Complete) (Exhaust System Replacement (Complete)).
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).